U.S. patent application number 11/935122 was filed with the patent office on 2008-05-22 for flexibly rigid personal protective equipment components.
Invention is credited to Brian Church, Dave Goldman, David B. Hook, Mark Howell, Thomas Leonard, James F. Walworth, Van T. Walworth, Craig Whitaker.
Application Number | 20080115387 11/935122 |
Document ID | / |
Family ID | 39415500 |
Filed Date | 2008-05-22 |
United States Patent
Application |
20080115387 |
Kind Code |
A1 |
Walworth; Van T. ; et
al. |
May 22, 2008 |
FLEXIBLY RIGID PERSONAL PROTECTIVE EQUIPMENT COMPONENTS
Abstract
The subject invention improves traditional safety equipment
intended to protect the lower leg, ankle, foot, and toes applicable
in industrial and commercial as well as casual and athletic uses.
The personal protective equipment (PPE) of the subject invention
comprises a soleplate, a metatarsal component, a toe cap, and a
tibia-fibula component; these components can be implemented alone
or in combination within a shoe or boot providing for various
levels of protection depending on the desired application. Further
embodiments provide for both the implementation of the protective
components within the footwear as well as components that can be
worn in conjunction with pre-existing shoes or boots.
Inventors: |
Walworth; Van T.; (Lebanon,
TN) ; Hook; David B.; (Franklin, TN) ;
Leonard; Thomas; (Geneva, OH) ; Whitaker; Craig;
(Fairfield, OH) ; Walworth; James F.; (Manhattan,
KS) ; Church; Brian; (Franklin, TN) ; Goldman;
Dave; (Towaco, NJ) ; Howell; Mark; (Lebanon,
TN) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Family ID: |
39415500 |
Appl. No.: |
11/935122 |
Filed: |
November 5, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60856927 |
Nov 6, 2006 |
|
|
|
60932272 |
May 30, 2007 |
|
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|
Current U.S.
Class: |
36/132 ; 36/72R;
36/77R |
Current CPC
Class: |
A43B 13/223 20130101;
A43B 23/086 20130101; A43C 13/14 20130101; A43B 7/32 20130101 |
Class at
Publication: |
36/132 ; 36/77.R;
36/72.R |
International
Class: |
A43B 5/00 20060101
A43B005/00; A43C 13/14 20060101 A43C013/14; A43B 13/22 20060101
A43B013/22 |
Claims
1. Protective components utilized in conjunction with footwear,
said protective components comprising at least one of the
following: a soleplate, said soleplate comprising at least one
layer positioned in the base of said footwear; a metatarsal
component, said metatarsal component comprising at least one
flexible plate, positioned in the top of said footwear, proximal
the metatarsals of a user wearing said footwear; a toe cap, said
toe cap comprising a rigid, deformable element positioned in the
front of said footwear; and a tibia-fibula component, said
tibia-fibula component comprising at least one vertical plate
positioned within the footwear proximal the tibia-fibula of the
user, wherein said protective components are manufactured from at
least one of the following materials: plastic, polycarbonates,
plastic polymers, metals, composites, fiberglass and Kevlar, said
protective components are implemented within said footwear during
the manufacturing and assembly of said footwear.
2. The protective components utilized in conjunction with footwear
of claim 1, wherein said footwear includes at least one of the
following: work boots, athletic shoes, combat boots, outdoor boots,
and casual shoes.
3. The protective components utilized in conjunction with footwear
of claim 2, wherein said soleplate comprises at least two layers,
said at least two layers are attached to each other utilizing
flexible adhesive, allowing adjacent layers to slip relative to one
another.
4. The protective components utilized in conjunction with footwear
of claim 3, wherein each of said at least two layers comprising
said soleplate further comprise at least one interlocking dart,
preventing one portion of said at least two layers from slipping
relative to one another.
5. The protective components utilized in conjunction with footwear
of claim 3, wherein said soleplate further comprises at least one
means for preventing over deflection of said soleplate.
6. The protective components utilized in conjunction with footwear
of claim 2, wherein said metatarsal component incorporates at least
one of the following: slots, structural breaks, or hinge points,
allowing flexibility in said metatarsal component.
7. The protective components utilized in conjunction with footwear
of claim 2, wherein said metatarsal component can be inserted into
the tongue of said footwear.
8. The protective components utilized in conjunction with footwear
of claim 2, wherein metatarsal component attaches externally to
said footwear.
9. The protective components utilized in conjunction with footwear
of claim 2, wherein said metatarsal component comprises at least
one of the following elements: plural overlapping plates, single
plates, multiple layer plates, ventilation holes, or pre-formed
crush ribs.
10. The protective components utilized in conjunction with footwear
of claim 2, wherein said tibia-fibula component incorporates at
least one of the following: slots, structural breaks, or hinge
points, allowing flexibility in said metatarsal component.
11. The protective components utilized in conjunction with footwear
of claim 2, wherein said tibia-fibula component can be inserted
into the tongue of said footwear.
12. The protective components utilized in conjunction with footwear
of claim 2, wherein tibia-fibula component attaches externally to
said footwear.
13. The protective components utilized in conjunction with footwear
of claim 2, wherein said tibia-fibula component comprises at least
one of the following elements: plural overlapping plates, single
plates, multiple layer plates, ventilation holes, pre-formed crush
ribs, plates of varying thickness, or a mosaic of rigid protection
structures interwoven with flexible hinge structures.
14. The protective components utilized in conjunction with footwear
of claim 2, wherein said toe cap comprises a curved-in flange
portion around the base of said toe cap, said curved-in flange
portion is slanted with an angled surface oriented at a beveled
angle relative to a bottom surface of said soleplate, said toe cap
further comprising a convex surface of the top of said toe cap,
said convex surface exhibiting at least one of the following
shapes: parabola, ellipse, arc, or series of straight flat surfaces
transitioning straight section to straight section via small
radiuses.
15. The protective components utilized in conjunction with footwear
of claim 14, wherein said curved-in flange portion of said toe cap
exhibits an included obtuse angle ".phi." expressed by the
relationship: 160.degree.<.phi.<180.degree..
16. The protective components utilized in conjunction with footwear
of claim 2, wherein said toe cap comprises a wall portion in
relation to said curved-in flange portion such that an obtuse angle
".beta." is formed between said wall and the underside of said
curved-in flange portion, said angle ".beta." can be expressed by
the relationship: 90.degree.<.beta.<100.degree., said obtuse
angle ".beta." tends to decrease in value approaching 90.degree.
when subjected to vertical crush forces, and said obtuse angle
".beta." tends to increase in value away from 90.degree. when
subjected to horizontal crush forces.
17. The protective components utilized in conjunction with footwear
of claim 2, wherein said toe cap comprises a plurality of holes
formed into the cap structure.
18. The protective components utilized in conjunction with footwear
of claim 2, wherein said toe cap comprises a series of
strengthening darts extending inward in said toe cap.
19. Protective components utilized in conjunction with footwear,
said protective components comprising at least one of the
following: a soleplate, said soleplate comprising at least one
layer positioned in the base of said footwear; a metatarsal
component, said metatarsal component comprising at least one
flexible plate, positioned in the top of said footwear, proximal
the metatarsals of a user wearing said footwear; a toe cap; said
toe cap comprising a rigid, deformable element positioned in the
front of said footwear; and a tibia-fibula component, said
tibia-fibula component comprising at least one vertical plate
positioned within the footwear proximal the tibia-fibula of the
user, wherein said protective components are manufactured from at
least one of the following materials: plastic, polycarbonates,
plastic polymers, metals, composites, fiberglass, and Kevlar, said
protective components comprise elements which can be worn in
conjunction with pre-manufactured footwear.
20. The protective components utilized in conjunction with footwear
of claim 19, wherein said footwear includes at least one of the
following: work boots, athletic shoes, combat boots, outdoor boots,
and casual shoes.
21. The protective components utilized in conjunction with footwear
of claim 20, wherein said soleplate comprises at least two layers,
said at least two layers are attached to each other utilizing
flexible adhesive allowing adjacent layers to slip relative to one
another.
22. The protective components utilized in conjunction with footwear
of claim 21, wherein each of said at least two layers comprising
said soleplate further comprise at least one interlocking dart
preventing one portion of said at least two layers from slipping
relative to one another.
23. The protective components utilized in conjunction with footwear
of claim 21, wherein said soleplate further comprises at least one
means for preventing over deflection of said soleplate.
24. The protective components utilized in conjunction with footwear
of claim 20, wherein said metatarsal component incorporates at
least one of the following: slots, structural breaks, or hinge
points, allowing flexibility in said metatarsal component.
25. The protective components utilized in conjunction with footwear
of claim 20, wherein said metatarsal component can be inserted into
the tongue of said footwear.
26. The protective components utilized in conjunction with footwear
of claim 20, wherein metatarsal component attaches externally to
said footwear.
27. The protective components utilized in conjunction with footwear
of claim 20, wherein said metatarsal component comprises at least
one of the following elements: plural overlapping plates, single
plates, multiple layer plates, ventilation holes, or pre-formed
crush ribs.
28. The protective components utilized in conjunction with footwear
of claim 20, wherein said tibia-fibula component incorporates at
least one of the following: slots, structural breaks, or hinge
points, allowing flexibility in said metatarsal component.
29. The protective components utilized in conjunction with footwear
of claim 20, wherein said tibia-fibula component can be inserted
into the tongue of said footwear.
30. The protective components utilized in conjunction with footwear
of claim 20, wherein tibia-fibula component attaches externally to
said footwear.
31. The protective components utilized in conjunction with footwear
of claim 20, wherein said tibia-fibula component comprises at least
one of the following elements: plural overlapping plates, single
plates, multiple layer plates, ventilation holes, pre-formed crush
ribs, plates of varying thickness, or a mosaic of rigid protection
structures interwoven with flexible hinge structures.
32. The protective components utilized in conjunction with footwear
of claim 20, wherein said toe cap comprises a curved-in flange
portion around the base of said toe cap, said curved-in flange
portion is slanted with an angled surface oriented at a beveled
angle relative to a bottom surface of said soleplate, said toe cap
further comprising a convex surface of the top of said toe cap,
said convex surface exhibiting at least one of the following
shapes: parabola, ellipse, arc, or series of straight flat surfaces
transitioning straight section to straight section via small
radiuses.
33. The protective components utilized in conjunction with footwear
of claim 32, wherein said curved-in flange portion of said toe cap
exhibits an included obtuse angle ".phi." expressed by the
relationship: 160.degree.<.phi.<180.degree..
34. The protective components utilized in conjunction with footwear
of claim 20, wherein said toe cap comprises a wall portion in
relation to said curved-in flange portion such that an obtuse angle
".beta." is formed between said wall and the underside of said
curved-in flange portion, said angle ".beta." can be expressed by
the relationship: 90.degree.<.beta.<100.degree., said obtuse
angle ".beta." tends to decrease in value approaching 90.degree.
when subjected to vertical crush forces, and said obtuse angle
".beta." tends to increase in value away from 90.degree. when
subjected to horizontal crush forces.
35. The protective components utilized in conjunction with footwear
of claim 20, wherein said toe cap comprises a plurality of holes
formed into the cap structure.
36. The protective components utilized in conjunction with footwear
of claim 20, wherein said toe cap comprises a series of
strengthening darts extending inward in said toe cap.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application Ser. No. 60/856,927, filed Nov. 6, 2006, and U.S.
Provisional Application Ser. No. 60/932,272, filed May 30, 2007.
The disclosures of the above applications are incorporated herein
by reference.
FIELD
[0002] This present disclosure relates to protective equipment for
personal use. More particularly, the present disclosure relates to
protective equipment pertaining to the lower leg, ankle, and foot
implemented with personal athletic and commercial footwear.
BACKGROUND
[0003] There are many applications of personal protective equipment
(PPE) components embedded into the fabrication of various shoes,
boots, protective guards, aprons, sheathing, vests, helmets,
gloves, and many other devices. Each of the above applications has
many specific applications in the marketplace. For example, work
boots may have a safety toe and/or a metatarsal shield and/or a
puncture-resistant sole and/or embed various devices to minimize
shock hazards, etc.
[0004] Each specific application has further applications based on
the type of materials used to construct the PPE components in the
various applications in which they are employed. Some common PPE
materials include metal, plastic, polymers, rubber, fiberglass,
wood, and/or various composites. In addition, materials such as
Kevlar and similar variants provide levels of protection against
ballistic penetration.
[0005] A specific application of a work boot is further expanded by
identifying that there are many varied applications of the boot,
such as manufacturing, heavy industrial, combat boots, jump boots,
hiking, fireman, muck boots, linemen, static dissipative,
shockproof, construction, snakebite, and many other specific
applications. Each of these applications requires a different set
of PPE components to address the needs of the user.
[0006] In addition to boots, PPE components are sometimes employed
into casual shoes, sports shoes, and other types of footwear. It is
improbable for one foot application to employ every version of PPE
available, rather that different footwear applications employ
appropriate PPE components to meet the need of the user.
[0007] In addition to footwear applications, there are applications
for PPE related to gloves, aprons, strap-on devices, vest, shields,
helmets, and many other PPE products. Each application implements a
unique set of PPE components to provide the user with a measure of
protection.
[0008] The disadvantages of current methods are numerous. One
disadvantage is that many PPE component applications are bulky,
heavy, or cumbersome, causing discomfort to the user. This
discomfort results in reduced satisfaction on the part of the user
and often results in the user not wearing the PPE safety
device.
[0009] Another disadvantage is that current methods do not provide
a ventilation means and/or they provide little or no insulation
potential.
[0010] Another disadvantage of the current methods is that the PPE
components require very rigid structures that correspondingly
restrict movement by the user and promote discomfort. For example,
work boots that employ puncture-resistant soles employ PPE
components that provide a puncture-resistant device that does not
promote flexibility along the arch portion of the foot. In similar
fashion, PPE components that provide a rigid shank device do not
promote flexibility for the rest of the foot.
[0011] Another disadvantage of the current methods is that there is
no safety toe cap designed to provide protection from lateral
crushing forces. For example, all current safety toe caps are
designed to resist a certain amount of vertical impact and vertical
crushing forces, but not one toe cap is designed to resist similar
lateral impact or lateral crushing forces.
[0012] A further disadvantage of the current methods is that a
measure of safety must be reduced in order to achieve flexibility
in certain PPE components. Also, the conflict between flexible PPE
components and rigid PPE components results in the employment of
multiple PPE components in the product application, which inflates
the costs of the final product and/or complicates the manufacture
of the product application, also inflating final production
costs.
[0013] Yet another disadvantage of the current methods is that the
materials used for many PPE components results in heavy structures
that give the wearer an un-natural feel using the device. However,
a reduction in weight of many PPE components results in reduced
protection.
[0014] Another disadvantage of the current methods is that the
expense of the PPE components limits the applications where they
can be implemented. For example, Kevlar is a material with good
ballistic penetration protection. It is also useful in
puncture-resistant soles of work boots. However, the PPE component
cost of Kevlar makes this material an unrealistic choice of
construction material for most mainstream consumer products.
[0015] Yet another disadvantage of the current methods is that the
PPE component materials do not lend themselves to alternate
applications of the component. For example, steel safety toe
components designed for heavy-duty applications do not have a
light-duty version available for the mainstream market. As a
result, light-duty applications seldom exist in the marketplace
because there are little or no practical PPE components available
for construction.
[0016] Still another disadvantage of the current methods is that
there is no method of providing a structure that is inherently
strong and yet lighter in weight compared to a similar structure
using the same materials.
[0017] Yet another disadvantage of the current methods is that no
viable safety toe cap designs are available that provide a
non-bulbous low-profile toe cap that still provides performance
requirements per ASTM or other similar standards. For example,
there are no low-profile, non-bulbous toe caps that can be
stylishly assembled into dress shoes or pointed cowboy boots that
still provide acceptable performance per ASTM standards.
[0018] Yet another disadvantage of the current methods is that
heavy-duty PPE components result in very cumbersome devices that
interfere with the user's ability to function. For example,
heavy-duty Kevlar vests protect the wearer from many
life-threatening ballistic penetrations, but with the penalty of
weight, lack of ventilation, and restricted movement. Another
disadvantage of this current method is that these same PPE
components have little or no known construction method for their
application to combat footwear. Therefore, a solider may be well
protected from upper body ballistic penetration and still be
vulnerable to lower leg and foot injuries.
[0019] Still another disadvantage of the current methods is that
many applications simply avoid employing PPE components because of
thermal problems with either heat sinks and/or cold sinks. As a
result, potential PPE advantages are not implemented, resulting in
reduced protection for the user. For example, combat boots often do
not contain a metal safety toe or metal puncture-resistant
soleplate because of both the thermal problems associated with the
metal as well as the problem of weight added to the boot. The
combination of these disadvantages leads to basic issue combat and
military boots not employing PPE components in the toe, metatarsal,
sole, or anywhere else in the boot. The metallic PPE components in
a combat boot potentially interfere with electrical components or
communication signals, while non-metallic applications of the
preferred embodiment prevent RFI and/or EMI problems.
[0020] Still another disadvantage of the current methods is that
there are no viable application solutions for sports shoes that
would prevent Turf Toe, an injury resulting from the toe of the
foot being hyper-extended during sports activities.
[0021] Yet another disadvantage of the current methods is that they
do not provide a viable relatively rigid soleplate section located
directly at the end of the toes of climbing shoes that provides a
suitable support for the toes of the foot when climbing in places
with very slight toe holds.
[0022] Still another disadvantage of the current methods is that
there are no viable application solutions for medical footwear that
prevents impalement from dropped scalpels and needles or other
sharp instruments during medical procedures.
[0023] Still another disadvantage of the current methods is that
there is no viable method to determine by visual or tactile means
whether PPE components have been compromised by an incidental
impact incident. For instance, safety toe caps can be subjected to
incidental impact forces that may or may not have cracked and/or
may or may not have compromised the toe cap's ability to maintain
appropriate safety performance ratings, and there is not a viable
non-destructive means for the wearer to evaluate the toe cap to
determine the integrity of the toe cap.
[0024] The disadvantages described above have similar scenarios in
every product application where PPE components are employed using
the current methods. While each application is different, the
disadvantages follow similar themes of excessive cost, thermal
problems, weight, and/or incompatibility of rigidity compared to
flexibility.
[0025] A further embodiment of the present invention covers toe
caps incorporated into personal footwear. Safety toe caps are
required in many industries for many different reasons. Toe caps
are designed to provide support protection from vertical crush
forces. Additional performance requirements, such as electrical
resistance, static resistance, chemical resistance, and the like,
have led toe caps to the development of many construction materials
other than steel.
[0026] Most workplace accidents that involve toe caps are the
result of vertical crush forces. Safety caps are specified and
required in many workplaces to provide personal protection for the
wearer in the event that the foot is subjected to a vertical crush
force.
[0027] However, a growing number of industry accidents occur each
year related to lateral crush forces acting against the foot. Such
accidents can take place when a worker gets his foot caught between
rolling pipe, between pallets, or between pieces of equipment. In
addition, a growing number of lateral side crush incidents take
place each year related to truck loading and unloading, or in the
construction industry where close quarters for foot placement
exist.
[0028] Traditional safety toe caps are designed to meet specific
performance requirements for vertical crush forces. If the same
vertical crush force were to be applied to a traditional toe cap,
the relative strength of the toe cap would only be about 20% of the
vertical crush force loads.
[0029] The subject invention overcomes the stated problems of prior
art toe caps and provides crush-resistant support against lateral
crush forces. In addition, the subject invention provides improved
structural performance against vertical crush forces.
[0030] The subject invention ushers in a new era of personal
protective footwear that provides unprecedented protection from
lateral side crush forces and will require that new standards be
written and new test methods be established that embody the
improved performance characteristics of this improved safety toe
cap.
[0031] Prior art forms of safety toe caps for safety shoes are
designed provide a measure of personal protection for the wearer in
the event that a vertical crush force is subjected to the shoe.
This protection provides a measure of protection to the toes and
foot of the wearer against vertical crush forces. Many designs of
toe caps exist in the global market place. Many construction
materials are used to manufacture toe caps, such as steel,
aluminum, plastics, fiberglass, composites, and other
materials.
[0032] There are many different grades of vertical crush-resistant
toe caps which are designed in compliance with various technical
specifications. For instance, there are ASTM standards, Canadian
standards, European standards, mining standards, military
specifications, and others. It is seldom, if ever, practical for
one toe cap design to meet all of the requirements of all the
various technical standards in the industry.
[0033] All of the technical standards include testing provisions
for vertical crush forces and appropriate minimum test requirements
that must be met to comply with each respective standard. All
safety toe caps used in the industry today are designed to comply
with one of these standards or a similar performance requirement
related to vertical crush forces.
[0034] While it is understood and recognized that the technical
standards also provide design requirements for electrical features,
impact, and chemical resistance, the focus of the subject invention
is related directly to the vertical crush force applications and
specifications of these technical standards.
[0035] Prior art safety toe caps all have a portion that covers
over the toes of the foot and wraps around the sides of the foot at
the toes. In addition, the prior art toe caps include a closed-toe
portion at the front end of the toes. Some prior art toe caps
include a portion that wraps further around the sides of the foot
to form a flange-type structure extending laterally inward under
the foot. The structural size and/or significance of the
flange-type structure varies greatly from toe cap design to toe cap
design, with many toe cap designs that have no evidence of the
flange-type feature.
[0036] Typical steel, aluminum, or metal toe caps usually feature a
uniform wall thickness everywhere in the cap, which is the most
economical method for metal forming process. Some metal castings
will feature different wall thicknesses in one portion of the toe
compared to other wall thicknesses in other portions of the toe
cap, which can provide improved strength in response to vertical
crush forces.
[0037] Some prior art forms of toe caps include the placement of
fibers in the toe cap walls to provide improved resistance to
vertical crush forces. Other toe cap designs provide thick nose
portions which are claimed to provide improved resistance to
vertical crushing forces.
[0038] One problem with prior art forms of toe caps is that the
current methods to improve the strength and performance of the toe
cap against vertical crush forces result in the toe cap being bulky
and bulbous, which makes the shoe undesirable to the wearer.
[0039] Another problem with prior art forms is that the extreme
lateral sides of the toe cap spread out in a further lateral
position relative to each other in response to vertical crushing
force, resulting in severe deformation and/or damage to the
shoe.
[0040] Another problem with prior art forms is that the extreme
lateral sides of the toe cap are driven down into the shoe in
response to vertical crush forces, resulting in reduced internal
vertical space for the foot and toes.
[0041] Another problem with prior art forms is that none of the
known toe caps are designed to provide support protection for the
wearer against lateral crush forces. None of the technical
standards provide a test procedure or a performance requirement
against lateral side crush forces.
[0042] The subject invention overcomes these problems and provides
additional improvements to safety toe caps that will be understood
and appreciated by those skilled in the art.
SUMMARY
[0043] It is therefore an objective of the subject invention to
provide PPE components that provide flexibility in portions of the
product application that require flexibility while at the same time
provide rigidity in portions of the product application that
require rigidity. For example, the present invention applied to PPE
components used as a puncture-resistant soleplate in a work boot
requires flexibility in the front portion of the component while at
the same time requiring a rigid portion of the same component in
the shank area under the arch of the foot.
[0044] It is an objective of the subject invention to provide PPE
components that are constructed of at least one layer. PPE
components constructed from multiple layers use combinations of
different materials to their advantage by creating structures with
physical properties greater than the individual properties of any
one layer. For example, a PPE puncture-resistant soleplate for a
work boot made from solid metal is relatively heavy and relatively
inflexible. However, a puncture-resistant soleplate with similar
puncture-resistant performance characteristics and flexibility
performance characteristics to that of solid metal can be achieved
with the subject invention by constructing multiple layers of
non-metal materials and/or sandwiching a thin metal layer between
other non-metal layers.
[0045] It is an objection of the subject invention to provide PPE
components for sports shoes that minimize and/or prevent Turf Toe
injuries by introducing reinforced ribs and/or darts and/or flange
structures into a soleplate under the toe portion of the foot and
extending back toward the ball of the foot area of the soleplate.
These reinforced structures may have alternate geometry
construction that changes the shape of the rib as it transverses
from the toe back toward the ball of the foot, including
potentially tapering and/or feathering to a blend at, near, or just
past the ball of the foot portion of the soleplate.
[0046] It is an objective of the subject invention to provide a
ventilation means for PPE components, such as metatarsal devices,
safety toes, Tib-Fib devices, mosaic structures, thumb and finger
PPE, arm and leg PPE, and other body PPE devices. Ventilation
features will enable increased comfort to the user. An alternative
to the ventilation feature is to provide an insulation chamber
within the PPE component structure.
[0047] It is an objective of the subject invention to take a layer
of material, that is not suitable for the desired performance
requirements on its own, and combine it with additional layers
and/or with additional materials to establish a PPE component that
exhibits performance results that exceed any material by itself.
For example, the thin metal layer of a work boot soleplate may be
flexible, but it does not provide appropriate puncture resistance
until it is encapsulated between the layers of non-metal materials,
resulting in a PPE component structure that is relatively
lightweight and relatively flexible, while still providing the same
or better puncture resistance as the solid metal layer of current
methods. In the same way, a thin metal soleplate layer may be
flexible, which will prevent it from providing shank support at the
arch, until it is encapsulated between layered components of the
subject invention.
[0048] It is another objective of the subject invention to take a
single layer of material that is flexible in certain portions of
the product application and modify the geometry of other portions
with a single layer of the product application to provide a rigid
structure. For example, a relatively thin metal soleplate applied
to a work boot for puncture resistance must have a certain amount
of flexibility for the foot to have a measure of comfort; however,
that same flexibility does not promote a shank support. Therefore,
the subject invention applied to the relatively thin metal
soleplate applies darts and/or rib structures to the soleplate in
the areas of the arch of the foot, providing shank support.
[0049] It is an objective of the subject invention to provide
biaxial interlocks between juxtaposed layers so as to form
geometric structures that provide rigid support in certain portions
of the product application while at the same time providing
interlocks, preventing relative rotation and/or slippage of the
layers relative to each other. For example, multiple layers of a
soleplate in a work boot might be manufactured from a relatively
thin polycarbonate material to provide flexibility for the front of
the foot, while darts and/or ribs are formed in the arch portion of
the soleplate to provide rigid shank support. A first series of
darts and/or ribs simultaneously provide shank support along with
relative registration of the layers in one linear direction.
Therefore, a second series of shank support darts and/or ribs are
formed, interlocking the layers such that the second series is
oriented relatively transverse to the first series, therefore
maintaining relative registration of the layers to each other. The
application of linear oriented transverse darts or ribs allows for
relative flexibility and slippage of one layer relative to another
layer in restricted areas where flexibility is required, while
simultaneously preventing relative registration slippage in the
rigid portions of the product application. For example, transverse
oriented darts and/or ribs interlocking layers of a soleplate in a
work boot allows flexibility in the front of the boot, provides
rigid shank support under the arch, allows slippage between layers
in the flexible portion of the soleplate, and prevents relative
slippage between layers in the rigid shank portion of the
soleplate. The transverse oriented ribs and/or darts prevent
relative slippage in the linear directions of the ribs as well as
preventing relative rotational slippage between the layers.
[0050] It is an objective of the subject invention to layer
preferred embodiments in such a way as to deflect incidental impact
away from the wearer. In much the same way that roofing shingles
are layered so the rain runs off the roof rather than run between
the layers, the preferred embodiment layers provide a measure of
deflection from incidental impact force, minimizing the potential
for the force to be directed toward the wearer.
[0051] It is an objective of the subject invention to provide
product applications in composite construction that combines the
rigid features of one material with the flexible features of
another material. For example, a rigid Kevlar component can be
embedded into a soleplate constructed from a flexible Kevlar
material. The composite nature of the construction provides
puncture resistance and/or shrapnel protection without sacrificing
flexibility or rigid requirements of the combat boot.
[0052] It is an objective of the subject invention to provide
product applications constructed from a relatively thin and
flexible layer with attached and/or integral rigid structures
spaced in such a way to allow flexibility of the relatively thin
layer, acting similar to a hinge portion between juxtaposed rigid
structures. The rigid structures provide a shape which meets the
strength requirements of a specific application. The rigid
structures can be integrally formed as part of the relatively thin
hinge layer, or they can be separately manufactured structures that
are applied to cooperate with the relatively thin hinge layer. For
example, a metatarsal PPE component can be constructed from a
relatively thin layer to provide flexibility of the metatarsal
component conforming to the foot curvatures, while the relative
rigid structures straddle the hinge areas and provide rigid support
and protection. The rigid structures provide a mosaic of armor
arranged straddle of hinge areas in the relatively thin layer. The
combination of the relatively thick armor combined with the
relatively thin hinge layer provides protection without sacrificing
flexibility. Variations of this preferred embodiment are also
enhanced with the incorporation of the layered deflection feature
disclosed above.
[0053] It is a further objective of the subject invention to
provide a light-duty metatarsal component and/or light-duty safety
toe and/or other light-duty components for sports shoes such as
football, soccer, rugby, hockey, and other contact activities where
incidental contact injuries to the foot are commonplace. Such
injuries can be minimized and/or avoided by incorporating
light-duty components of the subject invention that provide rigid
protection for the foot, while at the same time providing
flexibility for comfort and agility. Traditional metatarsal devices
are externally attached to the shoe; this construction method is
particularly disadvantageous for a sports shoe due to the potential
for being caught while wearing and causing a tripping hazard. The
preferred embodiment overcomes this shortcoming by being designed
to be embedded into the tongue of the shoe.
[0054] It is a further objective of the subject invention to
provide a wide variety of applications of light duty to heavy duty
PPE components for various industrial, sports, commercial,
manufacturing, skilled trades, military, first responder, and/or
medical applications of incidental contact devices for arm, chest,
head, back, leg, hand, finger, elbow, knee, neck, etc. Rigid
protection combined with flexibility for agility is paramount and
accomplished with various applications of the subject
invention.
[0055] It is an objective of the subject invention to provide a toe
cap with a structural member that acts in compression when
subjected to lateral side crush forces, but acts in tension when
subjected to vertical crush forces.
[0056] It is a further objective of the subject invention to
provide a toe cap with a structural member that provides improved
strength performance against vertical crush forces, such that the
toe cap design can be fine-tuned and made with thinner walls that
will still meet and comply with technical performance standards,
the resulting toe cap not being as bulbous or bulky as prior art
toe caps with the same crush rating.
[0057] It is a further objective of the subject invention to
provide a toe cap with a structural member that can be removed
and/or is a separate component to the toe cap.
[0058] It is a further objective of the subject invention to
provide a toe cap with a structural member that can be manufactured
from a different material than the toe cap.
[0059] It is a further objective of the subject invention to
provide a toe cap with a structural member that is integral with
the toe cap.
[0060] It is a further objective of the subject invention to
provide a toe cap with a structural member that is solid across the
entire under surface of the toe cap.
[0061] It is a further objective of the subject invention to
provide a toe cap with a structural member that is a brace or
columnar member.
[0062] It is a further objective of the subject invention to
provide a toe cap enhanced with downward extending tabs that
cooperate with a soleplate in such a way that vertical and/or
lateral crushing forces acting upon the toe cap are transmitted to
the soleplate and supported by a portion of the soleplate such that
the soleplate acts as a structural member for tension and
compression for the toe cap.
[0063] It is a further objective of the subject invention to
provide a toe cap with a structural member that has a slight convex
bow away from the bottom of the foot, so that when the member is
placed in compression, it will tend to continue to bow further away
from the foot and not arch up toward the foot. Correspondingly,
when the member is placed in tension, it will tend to straighten
out.
[0064] It is a further objective of the subject invention to
provide a toe cap with a structural member that has a non-planar
surface on the underside of the flange portions, which exhibits an
included obtuse angle ".phi." expressed by the relationship:
160.degree.<.phi.<180.degree..
[0065] It is a further objective of the subject invention to
provide a toe cap with a structural member that has rib-like cross
sectional shapes so that minimized wall thicknesses can be
utilized.
[0066] It is a further objective of the subject invention to
provide a toe cap with a structural member that is independent but
cooperates with the toe cap to positively lock and/or restrict the
open ends of the toe cap from moving outward or inward relative to
each other.
[0067] It is a further objective of the subject invention to
provide a toe cap with a structural member that said independent
member cooperates with the toe cap via any one of numerous
interlocking tabs. Said tabs may originate on the ends of the toe
cap, on the ends of the structural member, or both. The cooperation
between the structural member and the toe cap may be via a separate
component item, designed to facilitate cooperation between the toe
cap and the structural member, such as a lace, binding, staple,
hinge, mechanical interlock, etc.
[0068] It is a further objective of the subject invention to
provide a toe cap with a structural member that is positioned such
that it absorbs and/or dissipates vertical crush forces in a way
that prevents the walls of the toe cap from having to absorb the
brunt and totality of the crushing force. This feature is
accomplished via the individual contribution performance of the
convex structural member.
[0069] It is a further objective of the subject invention to
provide a toe cap with a structural member in which said included
obtuse angle ".phi." of the non-planar surface on the underside of
the flange portions tends to increase in value approaching
180.degree. when subjected to vertical crush forces, but will
decrease in value away from 180.degree. when subjected to vertical
crush forces.
[0070] It is a further objective of the subject invention to
provide a toe cap with a structural member that the convex surface
be a relative arc form, which may or may not be a true arc when the
toe cap is at rest, and void of any forces acting upon it. Said
relative convex surface may be deliberately in the shape of a
parabola, an ellipse, an arc, or a series of straight flat surfaces
transitioning straight section to straight section via small
radiuses. In addition, the relative convex shape can be
non-symmetrical in multiple planes and/or sections such that the
relative convex shape side-to-side across the foot (transverse to
the center line of the foot) might be different to the relative
cross-sectional shape oriented on the center line of the foot.
[0071] It is a further objective of the subject invention to
minimize and/or eliminate shoe construction components directly
under the toe cap, such as is often referred to as "red board",
which will save money, component inventory, assembly cost, and
assembly time.
[0072] It is a further objective of the subject invention to
provide a toe cap with a structural member with a flange portion
oriented non-planar relative to the vertical wall of the toe cap
such that an obtuse angle ".beta." is formed between the outside
wall and the underside flange portion. Said angle ".beta." can be
expressed by the relationship:
90.degree.<.beta.<100.degree..
[0073] It is a further objective of the subject invention to
provide a toe cap with a structural member in which said included
obtuse angle ".beta." of the non-planar surface on the underside of
the flange portions tends to decrease in value approaching
90.degree. when subjected to vertical crush forces, but will
increase in value away from 90.degree. when subjected to vertical
crush forces.
[0074] It is a further objective of the subject invention to
provide a toe cap with a structural member in which said included
obtuse angles ".phi." and ".beta." respond oppositely with respect
to each other in response to vertical and/or lateral crush
forces.
[0075] Further areas of applicability will become apparent from the
description provided herein. It should be understood that the
description and specific examples are intended for purposes of
illustration only and are not intended to limit the scope of the
present disclosure.
DRAWINGS
[0076] The drawings described herein are for illustration purposes
only and are not intended to limit the scope of the present
disclosure in any way.
[0077] FIG. 1a is a perspective view of the components comprising a
boot guard for combat or heavy industrial environments;
[0078] FIG. 1b is a perspective view of the components comprising a
boot guard for outdoor boots or snake-bite boots;
[0079] FIG. 1c is a perspective view of the components comprising a
boot guard for a typical work boot or tennis shoe style work
boot;
[0080] FIG. 1d is a perspective view of the components comprising a
boot guard for a typical shoe-style work boot for use in industrial
applications;
[0081] FIG. 2a is a perspective isolated view of a first embodiment
of the metatarsal component comprising a boot guard;
[0082] FIG. 2b is a perspective isolated view of a second
embodiment of the metatarsal component comprising a boot guard;
[0083] FIG. 2c is a perspective isolated view of a further
embodiment of the metatarsal component comprising a boot guard;
[0084] FIG. 2d is a perspective isolated view of a further
embodiment of the metatarsal component comprising a boot guard;
[0085] FIG. 2e is a perspective isolated view of a further
embodiment of the metatarsal component comprising a boot guard;
[0086] FIG. 2f is a perspective isolated view of a further
embodiment of the metatarsal component comprising a boot guard;
[0087] FIG. 2g is a perspective isolated view of a further
embodiment of the metatarsal component comprising a boot guard;
[0088] FIG. 2h is a perspective isolated view of a further
embodiment of the metatarsal component comprising a boot guard;
[0089] FIG. 3a is a perspective isolated view of a first embodiment
of the tibia-fibula component comprising a boot guard;
[0090] FIG. 3b is a perspective isolated view of a further
embodiment of the tibia-fibula component comprising a boot
guard;
[0091] FIG. 3c is a perspective isolated view of a further
embodiment of the tibia-fibula component comprising a boot
guard;
[0092] FIG. 3d is a perspective isolated view of a further
embodiment of the tibia-fibula component comprising a boot
guard;
[0093] FIG. 3e is a perspective isolated view of a further
embodiment of the tibia-fibula component comprising a boot
guard;
[0094] FIG. 3f is a perspective isolated view of a further
embodiment of the tibia-fibula component comprising a boot
guard;
[0095] FIG. 4a is a partial perspective view of a first embodiment
of the soleplate of the present invention;
[0096] FIG. 4b is a partial perspective view of a further
embodiment of the soleplate of the present invention;
[0097] FIG. 4c is a partial perspective view of a further
embodiment of the soleplate of the present invention;
[0098] FIG. 5a is a perspective view of a further embodiment of the
soleplate of the present invention;
[0099] FIG. 5b a is a partial perspective view of soleplate shown
in FIG. 5a in the deflected orientation;
[0100] FIG. 5c is a perspective underside view of the soleplate
embodiment shown in FIG. 5a;
[0101] FIG. 6 is a perspective view of a further embodiment of the
soleplate of the present invention;
[0102] FIG. 7a is a perspective view of a further embodiment of the
present invention comprising a closed-toe cap;
[0103] FIG. 7b is a perspective view of a further embodiment of the
present invention comprising an open-bottom toe cap;
[0104] FIG. 7c is a perspective view of a further embodiment of the
present invention comprising a toe cap implementing a plurality of
weight minimizing/ventilation holes; and
[0105] FIG. 7d is a perspective view of an open-bottom toe cap
implementing a plurality of weight minimizing/ventilation slots and
strengthening darts.
DETAILED DESCRIPTION
[0106] The following description is merely exemplary in nature and
is not intended to limit the present disclosure, application, or
uses. It should be understood that throughout the drawings,
corresponding reference numerals indicate like or corresponding
parts and features.
[0107] The subject invention has many preferred embodiments using a
wide variety of construction materials, such as metal, plastic,
polymers, composites, fiberglass, Kevlar type materials, and others
familiar to those skilled in the art. Each material brings with it
manufacturing techniques synonymous with that particular material
and/or combination of materials.
[0108] For instance, metal components can be cast, forged,
machined, stamped, etc. Plastic, polycarbonates, and polymers can
be formed from sheets, molded, extruded, heat shaped, vacuum
formed, blow molded, etc. Kevlar type materials and other exotic
materials require processes that are consistent with that material
to fabricate PPE components using the features of the subject
invention.
[0109] Therefore, typical construction methods are used according
to the selected construction materials employed for the
application. Those skilled in the art of construction materials and
manufacturing processes will appreciate that the subject invention
can be manufactured using any one of many standard practices and
techniques.
[0110] Referring now to the drawings, in particular FIGS. 1a-1d,
the preferred embodiments of the subject invention are shown
comprising a boot/shoe guard 10, having a soleplate 20, a
metatarsal component 30, a toe cap 40, and a tibia-fibula component
50. These components can be implemented alone or in combination
within a shoe or boot, providing for a varied level of protection
depending on the application.
[0111] The soleplate 20 provides a puncture-resistant layer on the
bottom of the footwear, which can comprise a single layer or
multiple layers secured together by adhesive. In the event that
multiple layers are embodied, the adhesive utilized is flexible,
allowing portions of adjacent layers to slip relative to each other
during flexing while preventing other portions from slipping by
providing interlocking ribs or darts 21. Said darts or rib
structures provide interlocking features as well as rigid shank
support in a specified portion of the soleplate. Other preferred
embodiments employ adjacent layers with similar flexible features
disclosed for the previous embodiment, but do not provide
interlocking ribs. Instead, this embodiment provides one layer with
ribs or darts and uses a fastening means, such as an adhesive film,
gel, or other fastening means, to secure the adjacent layers in the
rigid shank support portion. The rib or dart forms a triangle or
arc-type cross section with the cooperating plate. The secure
connection between the adjacent layers provides a strong structural
cross-sectional geometry for the shank support portion.
[0112] In addition to PPE, variations of the above embodiment have
potential applications for improved manufacture of
composite-layered skateboards, surfboards, diving boards,
construction and/or structural components, aircraft wing
components, stadium seats, modular furniture, and many other
applications.
[0113] Referring back now to FIGS. 2a-2h, another element of the
present invention is shown in several embodiments showing a
metatarsal PPE component 30 that provides rigid incidental impact
protection while at the same time providing some flexibility for
agility and comfort. The preferred embodiment incorporates slots,
structural breaks, or hinge points that allow flexibility in
designated locations and directions. The component embodiment has a
light-duty version that can be inserted into the tongue of the
shoe, hiding its presence from view, and yet providing a measure of
metatarsal protection. A typical heavy-duty version of the
embodiment attaches externally similar to traditional metatarsal
devices, but provides the feature of flexibility, providing extra
comfort and agility to the wearer. The metatarsal components can
comprise various elements, such as plural overlapping plates,
single or multiple layer plates, ventilation holes, or pre-formed
crush ribs.
[0114] Referring now to FIGS. 3a-3f, a further element of the
present invention is shown in several embodiments showing
structural tibia-fibula PPF components 50 that can be incorporated
into, onto, and/or slipped inside of a boot, such as a combat boot,
jump boot, first responder boot, etc., providing protection to the
Tib-Fib portions of lower leg. These components provide flexibility
from specifically oriented and/or located hinges 52 and/or
thick-thin portions that form a mosaic of rigid protection
structures interwoven with flexible hinge structures. Preferred
embodiments of this application provide protection for combat boots
from projectiles initiated from improvised explosive devices (IED).
The protection is designed to minimize certain lower leg injuries
that might have otherwise resulted in the loss of limbs.
[0115] Referring now to FIGS. 4a-4c, further embodiments of the
soleplate are shown. In traditional sports and athletic shoes, the
evolution of the cleat from a traditional 7-cleat shoe containing a
steel plate in the sole to a more flexible soccer-style shoe to
artificial turf shoes have increased speed at the price of
stability. The absence of a stiff soleplate, especially under the
metatarsal phalangeal (MTP) joints, places an athlete at greater
risk of injury. This often comes from rolling of the ball of the
foot, as well as jamming of the toes during athletic maneuvers. As
shown in FIGS. 4a-4c, one or more darts or ribs 24 are formed
within the soleplate 20 either alone or in combination proximal the
big toe to improve rigidity of the soleplate 20. This embodiment of
soleplate can be built into the construction of the shoe and/or
applied to a "loose insert" insole application.
[0116] FIGS. 5a through 5c illustrate a further embodiment of the
soleplate, wherein structurally integrated deflection limiters 26
and 28 are formed with the soleplate 20 on either side of the
soleplate, proximal the ball of the foot. These prevent the
soleplate 20 from over deflection during athletic maneuvers,
causing serious injuries. Foam, padding, or fabric is positioned
between the limiters 26 and 28 to prevent a pinch point. This
embodiment is intended to be built into the construction of the
shoe.
[0117] Referring now to FIG. 6, a further embodiment of the
soleplate of the present invention is shown. In this embodiment, a
lip or flange portion 27 is on the toe end of the soleplate and at
the heel end 29 of the soleplate. The lip or flanges 27, 29 are
easily stamped as part of the formation of the soleplate, along
with the integral shank darts 25. The presence of the darts 25
provides some resistance to shift in the longitudinal axis while
providing increased support and stability.
[0118] A further embodiment of the subject invention provides a
safety toe cap 40 that incorporates a curved-in flange portion 41
around the base of the safety toe that is deliberately slanted with
an angled surface that is oriented at a slightly beveled angle
relative to the surface of the soleplate as shown in FIGS. 7a and
7b. The curved-in flange portion which exhibits an included obtuse
angle ".phi." is expressed by the relationship:
160.degree.<.phi.<180.degree.
[0119] This provides a toe cap 40 with a structural member that is
positioned such that it absorbs and/or dissipates vertical crush
forces in a way that prevents the walls of the toe cap from having
to absorb the brunt and totality of the crushing force.
[0120] The toe cap with said included obtuse angle ".phi." of the
non-planar surface on the underside of the flange portions tends to
increase in value approaching 180.degree. when subjected to
vertical crush forces, but will decrease in value away from
180.degree. when subjected to horizontal crush forces.
[0121] The convex surface of the top of the toe cap 40 may be of
relative arc form and may or may not be a true arc when the toe cap
is at rest and void of any forces acting upon it. Said relative
convex surface may be deliberately in the shape of a parabola or an
ellipse, an arc, or a series of straight flat surfaces
transitioning straight section to straight section via small
radiuses. In addition, the relative convex shape can be
non-symmetrical in multiple planes and/or sections such that the
relative convex shape side-to-side across the foot (transverse to
the center line of the foot) might be different to the relative
cross-sectional shape oriented on the center line of the foot.
[0122] The toe cap is designed to be utilized within shoes without
the use of the commonly necessary `red board` often utilized for
structural support due to the base of the toe cap joining the outer
walls under the toes.
[0123] The toe cap 40 further defines the wall portion in relation
to the flange portion 41 oriented relative to the vertical wall of
the toe cap such that an obtuse angle ".beta." is formed between
the outside wall and the underside flange portion. Said angle
".beta." can be expressed by the relationship:
90.degree.<.beta.<100.degree.
[0124] This provides the toe cap with a structural member in which
said included obtuse angle ".beta." of the non-planar surface on
the underside of the flange portions tends to decrease in value
approaching 90.degree. when subjected to vertical crush forces, but
will increase in value away from 90.degree. when subjected to
horizontal crush forces. Obtuse angles ".phi." and ".beta." respond
oppositely with respect to each other in response to vertical
and/or lateral crush forces.
[0125] This slightly beveled angle forms an interior wall angle
greater than 90.degree. relative to the inside wall of the safety
toe. In the event of incidental impact, the beveled flange portion
is in a position to flex in such a way that the
greater-than-90.degree. angle is compressed toward the 90.degree.
point. This compression results in the absorption of the initial
impact force, reducing the impact force. The rest of the structure
dissipates the remainder of the impact force away from the
foot.
[0126] Referring now to FIGS. 7c and 7d, a further embodiment of
the toe cap 40 is illustrated. In these illustrations, the toe cap
40 has either a plurality of holes 42 or slots 43, either molded
into the cap structure or machined into the cap after
manufacturing. These apertures reduce the overall weight of the toe
cap 40 without significantly sacrificing the integrity and
protection the toe cap provides. In addition to reducing the
overall weight of the toe cap 40 by up to 10%, these holes 42 and
slots 43 further provide ventilation within the toe cap by allowing
air to passively circulate in and out of the cap.
[0127] Further shown in FIG. 7d, an additional feature of the toe
cap 40 may include a series of strengthening darts 44 extending
inward in the cap, providing additional integrity to the toe cap
40. These features may be implemented on either the closed-toe cap
embodiment or the open-bottom toe cap having the flange portion 41
shown in FIG. 7b, depending upon the desired application.
[0128] The preferred embodiments of the subject invention may
employ a wide variety of construction materials, such as metal,
plastic, polymers, composites, fiberglass, Kevlar type materials,
and others familiar to those skilled in the art. Each material
brings with it manufacturing techniques synonymous with that
particular material and/or combination of materials.
[0129] For instance, metal components can be cast, forged,
machined, stamped, etc. Plastic, polycarbonates, and polymers can
be formed from sheets, molded, extruded, heat shaped, vacuum
formed, blow molded, etc. Kevlar type materials and other exotic
materials require processes that are consistent with that material
to fabricate PPE components using the features of the subject
invention.
[0130] Alternative methods to apply resilient adhesives using
epoxy, films, glue, sealants, etc, are plentiful, and those skilled
in the art will readily appreciate the spirit of the subject
invention and how numerous construction techniques can be drawn
upon to facilitate embodiment applications of the subject
invention.
* * * * *